Disclosed is a coating material for coating a surface of a kiln for preparing an active material, the coating material being represented by the following Formula 1:

Ni.sub.aX.sub.z  (1) wherein an equation of a+z=1 is satisfied, with the proviso that 0.2≤a<1.0 and 0<z≤0.8 are satisfied, and X is at least one element selected from the group consisting of W, Cr, Co, Fe, Cu, Na, Al, Mg, Si, Zn, K, Ti, Mo, N, B, P, C, Ta, Nb, O, Mn, Sn, Ag and Zr, or an alloy or compound of two or more elements selected therefrom.

A powder material includes: an atomized powder of an Ni-based alloy containing inclusions, in which a number of particles of the contained inclusions is 100 particles or less per 10,000 particles of the atomized powder. The Ni-based alloy may include at least one additive element selected from Al, Ti and Nb, and the inclusions include at least one of oxide and carbonitride of the additive element.

Provided is a brazing filler material for bonding iron-based sintered member that includes a sintered compact containing Cu, Mn, and a remainder of Ni and unavoidable impurities, and an oxide film formed on a surface of the sintered compact. An oxygen concentration may account for not less than 0.1% by mass of a total amount of the brazing filler material. The oxide film may contain Mn.

A titanium-free cobalt-chromium alloy for a powder, contains (in wt.%) C 0.40 -1.50%, Cr 24.0 - 32.0%, W 3.0 - 8.0%, Mo 0.1 - 5.0%, where 4.0 < W + Mo < 9.5 is satisfied by the content of W and Mo in wt.%, Nb max. 0.5%, Ta max. 0.5 %, where Nb + Ta < 0.8 is satisfied by the content of Nb and Ta in wt.%, Ni 0.005 - 25.0%, Fe 0.005 -15.0%, where Ni + Fe > 3.0 is satisfied by the content of Ni and Fe in wt.%, Mn 0.005 -5.0%, Al max. 0.5%, N 0.0005 - 0.15%, Si < 0.3%, Cu max. 0.4%, O 0.0001 - 0.1%, P max. 0.015%, B max. 0.015%, S max. 0.015%, residual Co, and impurities resulting from the production process, in particular Zr max. 0.03% and Ti max. 0.025%.

A method of furnace-less brazing of a substrate is provided. The method includes providing a substrate having a braze region thereon; disposing braze precursor material containing a nickel powder, an aluminum powder, and a platinum group metal powder on the braze region; and initiating an exothermic reaction of the braze precursor material such that the exothermic reaction produces a braze material that reaches a braze temperature above the solidus temperature of the braze material. A braze precursor material is also provided.

A method of furnace-less brazing of a substrate is provided. The method includes providing a substrate having a braze region thereon; disposing braze precursor material containing a nickel powder, an aluminum powder, and a platinum group metal powder on the braze region; and initiating an exothermic reaction of the braze precursor material such that the exothermic reaction produces a braze material that reaches a braze temperature above the solidus temperature of the braze material. A braze precursor material is also provided.

A method for removing powder from a component or part produced by metal additive manufacturing systems based on powder beds. The method includes manufacturing a part by additive manufacturing, the part having at least one internal cavity with at least one external opening. The internal cavity is at least partly filled with powder, the powder in the internal cavity having grains agglomerated or connected to each other. The method further including: evacuating gas from the internal cavity; adding liquid electrolyte to the internal cavity, and using an electrochemical process for separating connected powder grains in the cavity.

The present invention concerns nickel alloys in powder form comprising at least 40 wt.-% Ni, about 20.0 to 25.0 wt.-% Cr, about 5.0 to 25.0 wt.-% Co and about 1.5 to 5.0 wt.-% Ti, which have a content of B in an amount of less than 40 ppmw. Corresponding alloys have the advantage of providing minimal or no micro-cracks as well as an improved ductility in creep conditions compared to similar alloys having a higher content of B, when the alloys are processed by additive manufacturing to prepare three-dimensional objects. The present invention further concerns processes and devices for the preparation of three-dimensional objects from such nickel alloy powders, processes for the preparation of corresponding nickel alloy powders, three-dimensional objects which are prepared from such nickel alloy powders and the use of such nickel alloy powders to minimize and/or suppress micro-crack formation and/or to provide improved creep ductility.

A method for preparing the prefabricated crack defects includes defining a defect area, defining a volume percentage of the crack defects in the defect area, adjusting the proportion of spherical powder, the proportion of hollow powder and process parameters of defect preparation according to the volume percentage of the crack defects, based on the technique of laser melting deposition, printing the defect area layer by layer by using the defect preparation powder and the process parameters of defect preparation, wherein the particle size of the defect preparation powder is between 45 μm and 150 μm, the proportion of spherical powder≥93% and the proportion of hollow powder<0.5%, the process parameters of defect preparation including: laser power of 450W-550W, scanning rate of 600 mm/min-1200 mm/min, powder feeding rate of 4 g/min-12 g/min, spot diameter of 1 mm-1.2 mm, scanning spacing of 0.5 mm-0.8 mm and layer thickness of 0.08 mm-0.2 mm.

Disclosed herein are embodiments of methods, devices, and assemblies for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertains to scrap materials, dehydrogenated or non-hydrogenated feed material, recycled used powder, and gas atomized powders. Microwave plasma processing can be used to spheroidize and remove contaminants. Advantageously, microwave plasma processed feedstock can be used in various applications such as additive manufacturing or powdered metallurgy (PM) applications that require high powder flowability.